CN110605390A - Wire forming method for metal additive manufacturing - Google Patents
Wire forming method for metal additive manufacturing Download PDFInfo
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- CN110605390A CN110605390A CN201910742195.XA CN201910742195A CN110605390A CN 110605390 A CN110605390 A CN 110605390A CN 201910742195 A CN201910742195 A CN 201910742195A CN 110605390 A CN110605390 A CN 110605390A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/22—Direct deposition of molten metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/80—Data acquisition or data processing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/40—Radiation means
- B22F12/49—Scanners
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- General Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Automation & Control Theory (AREA)
- Laser Beam Processing (AREA)
Abstract
A method of wire forming for metal additive manufacturing, comprising the steps of: 1) setting parameters; 2) slicing; 3) splitting laser beams; 4) shading light; 5) and (5) forming the part. The invention improves the heating mechanism in the part forming process, makes the temperature field distribution more uniform, and reduces the temperature gradient, thereby reducing the generation of the defects of warping and breaking of the part caused by thermal stress and thermal deformation after the part is formed; line forming can directly form a path of a layer of cross section of a part, and then the part is stacked and formed layer by layer. Therefore, the linear array forming process is simpler, and the metal additive manufacturing efficiency can be improved.
Description
Technical Field
The invention relates to the field of metal additive manufacturing, in particular to a metal additive manufacturing line forming method.
Background
In the field of advanced manufacturing technology, the additive manufacturing technology is concerned by the fact that the additive manufacturing technology has the characteristics that the additive manufacturing technology is accumulated layer by layer from top to bottom, the purchase-flight ratio can reach 1:1 under an ideal condition, a digital model can be quickly converted into an actual product, and the like. Generally, the production requirements for metal parts are higher compared to non-metal parts, both manufacturing processes and production equipment. With the development of society, the personalized demand of the market for products is higher and higher, which makes the metal additive manufacturing technology an important branch of the additive manufacturing technology. The most widely used energy source in metal additive manufacturing is laser, a laser spot is formed in the forming process, the size of the laser spot can be set, a layer of molten metal powder is formed point by point according to the shape of a part, the forming process is that the laser spot scans and forms one path point by point according to the shape of a section and then scans and forms the next path point by point, and the steps are repeated until the forming of the section is completed. Then, from bottom to top, each section is formed by scanning all paths on the section point by laser spots. The above-described forming process can be summarized as "from point to line, bottom to top, layer by layer stacking". However, the point-to-line forming process causes the problem that the formed part is warped, deformed and broken due to uneven temperature field distribution.
The point-to-line forming process is the main cause of warping deformation and fracture of the parts. For the same path, the position scanned by the laser spot is suddenly subjected to high energy, the temperature rises, and when the spot scans to the next position, the temperature at the previous position gradually decreases. And according to the scanning path, continuing to form the next point after the laser forming is finished. The temperature of the upper point is already reduced and the temperature of the lower point is suddenly increased, so that the cold end and the hot end of the same road path are caused. The cold end and the hot end of the same path can cause large thermal stress in the part, thereby causing deformation and even breakage of the formed part. For two different adjacent paths, the temperature of the initial point of the previous path is already reduced, and the initial point of the forming path is suddenly subjected to high energy by laser scanning, and the temperature is increased, so that a large temperature gradient is generated. Similarly, such temperature gradients not only occur at the beginning and end of the two forming paths, but also exist in the whole forming path. Therefore, the scanning time is short, so that the temperature fields of all areas in the whole forming process have the characteristic of uneven distribution. As shown by the point-to-line forming process shown in fig. 1 and 2. It is assumed that the cross-sectional shape of a layer during the forming process is triangular ABC as shown in the drawing. During forming, the laser beam firstly transmits high energy to the powder at the position a in a very short time to melt the powder; the laser beam then continues to scan, completing the scan of path 1 when it reaches b. At this time, the temperature at a has already dropped and the temperature at b has suddenly risen relative to the same path ab, and the temperature field distribution in the path 1 exhibits the characteristics of lower temperature at a and higher temperature at b. Similarly, after completing the scan of path 1, the laser beam continues to complete the scan of path 2, first, delivering a very high energy to the powder at c for a very short time to melt it, and completing the scan of path 2 when it reaches d. Thus, point a on path 1 has already decreased in temperature relative to the different paths 1, 2, while point c on path 2 has just been scanned, the temperature suddenly rises, and there is also a large temperature gradient between the ac. In summary, there is a large temperature gradient, either within the same path or between different paths, when forming the entire part. Due to the thermal forming mechanism, the temperature field distribution is uneven and the temperature gradient is large in the part forming process. The large temperature gradient makes the heated part of the part expand and deform during molding, theoretically, the heated and expanded part should shrink into a normal shape when the temperature is reduced, but because the dissipation process of energy is complex, the molded part after cooling actually has great thermal stress, so that the final molded part has the defects of warping, breaking and the like.
Disclosure of Invention
In order to overcome the defects of uneven temperature field distribution, large temperature gradient generated formed part warping, fracture and the like in the metal additive manufacturing process of the existing point forming, the invention provides a metal laser additive manufacturing method of line forming, which can improve the temperature field distribution and the temperature gradient in the part forming process and simultaneously improve the manufacturing efficiency.
The technical scheme adopted by the invention for solving the technical problems is as follows:
a method of wire forming for metal additive manufacturing, comprising the steps of:
1) setting parameters: firstly, setting the beam splitting number m of laser in the x direction; secondly, setting the spot size of the original laser beam according to the required precision and shape conditions of the formed part so as to control the spot size of the split laser; finally, setting parameters of laser power, linear energy density and scanning speed according to different molding materials;
2) and (3) slicing treatment: importing a printable CAD model of the part into slicing software matched with printing equipment, designing corresponding parameters according to the step 1), and then carrying out slicing processing on a given layer thickness, wherein the slicing direction is assumed to be the z-axis direction, and obtaining two-dimensional layer information in the z-direction after slicing;
3) laser beam splitting: splitting the beam in the x direction to split the laser, wherein the original laser beam is emitted from a vibrating mirror of the additive manufacturing equipment and then passes through an x-direction lattice laser beam splitter, and the split number is m;
4) shading light: forming a laser linear array by splitting the original laser beam in the step 2), wherein the linear array shapes required when different paths are formed are different, and at the moment, closing of corresponding laser beam channels is controlled by a light chopper; when the part is molded, controlling the angle of a reflector at the corresponding position on the light shield according to the two-dimensional layer information in the z direction obtained after slicing in the step 2) so that the laser beam passes through or is reflected to the light absorption unit;
5) forming parts: obtaining corresponding shading control information according to the slice file obtained in the step 1), firstly obtaining a dimmer control data file according to the shading control information obtained from each layer of section, wherein the content of the data file is the simplest 0/1 code and represents the opening and closing of a shading hole; when the part forming is started, the controller reads the shutter control data of the first path, and controls the angle of the reflector according to 0/1 codes so as to determine whether the laser passes through the light shielding plate or is reflected and absorbed; and after the molding of the first path is finished, the data memory of the shading controller moves to the shading controller data of the second path to read, and whether the laser passes through the shading plate is controlled according to 0/1 codes, so that the process is continuously and repeatedly executed until the molding of the whole part is finished.
Further, in the step 5), for higher requirement on the forming accuracy, the content of the controller data file is no longer only a simple 0/1 code obtained according to the shading control information obtained from each layer of section, but each data unit obtained according to the shading control information and the setting of process parameters is a two-dimensional matrix data file with data accuracy of 8 bits or even higher, and the information stored in each data unit includes the opening and closing of the shading hole, the laser power, the laser aperture and the scanning speed; the controller is used for controlling the opening and closing of the light shield according to the data file, and adjusting all control modules in the whole forming process according to corresponding process parameters set by forming requirements of different positions of a formed part.
Still further, in the step 4), the process of controlling the closing of the corresponding laser beam channel by the shutter is as follows: and 2) passing the laser linear array obtained in the step 2) through a light chopper, wherein the light chopper is structurally characterized in that m controllable reflectors which are the same as the laser linear array beam are arranged on a light shielding plate, and the aperture size of the light chopper is set to be the aperture size of the maximum facula of the beam-splitting laser.
The invention has the following beneficial effects:
1) the heating mechanism in the part forming process is improved, the temperature field distribution is more uniform, and the temperature gradient is reduced, so that the defects of warping and breaking of the part caused by thermal stress and thermal deformation after the part is formed are reduced.
2) Compared with the traditional forming method of laser dot matrix scanning from point to line, from bottom to top and stacking layer by layer, the line forming can directly form a path of a layer section of the part, and then the part is stacked layer by layer for forming. Therefore, the linear array forming process is simpler, and the metal additive manufacturing efficiency can be improved.
3) The forming process parameters of each path can be set according to the forming precision requirement, so that the manufacturing process has higher controllability.
In addition, the invention is suitable for various metal powder materials such as stainless steel, cobalt-chromium alloy, pure titanium, titanium alloy and the like.
Drawings
Fig. 1 is a schematic view a of a point-to-line formation.
Fig. 2 is a schematic view b of the point-to-line formation.
Fig. 3 is a schematic diagram of a line shaping laser light path.
Fig. 4 is a schematic view of line formation.
FIG. 5 is a schematic view of a laser array after shading
Figure 6 is a schematic view of the shutter principle.
FIG. 7 is a laser control flow chart for line forming
FIG. 8 is a flow chart of line formation
In the figure, 1-original laser beam, 2-laser emitter, 3-X direction laser beam splitter, 4-light chopper, 5-X direction beam splitting laser and 6-laser linear array.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
Referring to fig. 1 to 8, a wire forming method for metal additive manufacturing includes the following steps:
1) setting parameters: compared with the traditional parameter setting of metal additive manufacturing, the method needs parameters related to laser beam control. According to the molding requirement, firstly, setting the beam splitting number m of the laser in the x direction; secondly, setting the spot size of the original laser beam according to the conditions of precision, shape and the like required by the formed part so as to control the spot size of the split laser; finally, the parameters of laser power, linear energy density, scanning speed and the like are set according to different molding materials.
2) And (3) slicing treatment: and (2) importing the printable CAD model of the part into slicing software matched with printing equipment, designing corresponding parameters according to the step 1), and then carrying out slicing processing on the given layer thickness, wherein the slicing direction is assumed to be the z-axis direction, and the two-dimensional layer information in the z-direction can be obtained after slicing.
3) Laser beam splitting: laser beam splitting is performed in the x-direction. The original laser beam is emitted from a 2-galvanometer of the additive manufacturing equipment and then passes through a 3-x direction lattice laser beam splitter, and the beam splitting quantity is m beams.
4) Shading light: the original laser beam is divided into 5-laser linear arrays after passing through the step 2), the linear arrays required by forming different paths are different in shape, and at the moment, the closing of corresponding laser beam channels is controlled by a 4-shutter, and the specific process is as follows. And 2) passing the laser linear array obtained in the step 2) through a 4-light chopper, wherein the light chopper is structurally characterized in that m controllable reflectors which are the same as the laser linear array beam are arranged on a light shielding plate. It should be particularly noted that the aperture size on the shutter should be set to the aperture size of the maximum spot of the split laser light. When the part is molded, the angle of the mirror at the corresponding position on the shutter is controlled based on the two-dimensional slice information in the z direction obtained after slicing in step 2) so that the laser beam passes through or is reflected toward the light absorption unit.
5) Forming parts: corresponding shading control information can be obtained according to the slice file obtained in the step 1). The simplest case is to obtain the shutter control data file according to the shutter control information obtained from each layer section, and the data file content is the simplest 0/1 code and represents the opening and closing of the shutter holes. When the part forming is started, the controller reads the shutter control data of the first path, and controls the angle of the reflector according to 0/1 codes so as to determine whether the laser passes through the light shielding plate or is reflected and absorbed. When the first path is finished, the shutter controller dataram is moved to the shutter control data of the second path for reading, and whether the laser passes through the shutter plate is controlled according to 0/1 codes. Thus, the process is continuously and repeatedly executed until the whole part is formed. And a more accurately controlled forming system can be adopted for parts with higher forming precision requirements. The overall forming process is basically the same as that described above, and the difference is that the content of the controller data file is no longer simply 0/1 code obtained from the shading control information obtained from each layer section, but is a two-dimensional matrix data file with data accuracy of 8 bits or even higher for each data unit obtained from the shading control information and the setting of process parameters, and the specific data accuracy is determined according to the process parameters to be controlled. The information stored in each data unit may include opening and closing of the light shielding holes, laser power, laser aperture, scanning speed, and the like. The controller is used for controlling the opening and closing of the light shield according to the data file, and adjusting all control modules in the whole forming process according to corresponding process parameters set by forming requirements of different positions of a formed part.
The above embodiments are only preferred embodiments of the present invention, and are not intended to limit the technical solutions of the present invention, so long as the technical solutions can be realized on the basis of the above embodiments without creative efforts, which should be considered to fall within the protection scope of the patent of the present invention.
Claims (3)
1. A method of wire forming for metal additive manufacturing, the method comprising the steps of:
1) setting parameters: firstly, setting the beam splitting number m of laser in the x direction; secondly, setting the spot size of the original laser beam according to the required precision and shape conditions of the formed part so as to control the spot size of the split laser; finally, setting parameters of laser power, linear energy density and scanning speed according to different molding materials;
2) and (3) slicing treatment: importing a printable CAD model of the part into slicing software matched with printing equipment, designing corresponding parameters according to the step 1), and then carrying out slicing processing on a given layer thickness, wherein the slicing direction is assumed to be the z-axis direction, and obtaining two-dimensional layer information in the z-direction after slicing;
3) laser beam splitting: splitting the beam in the x direction to split the laser, wherein the original laser beam is emitted from a vibrating mirror of the additive manufacturing equipment and then passes through an x-direction lattice laser beam splitter, and the split number is m;
4) shading light: forming a laser linear array by splitting the original laser beam in the step 2), wherein the linear array shapes required when different paths are formed are different, and at the moment, closing of corresponding laser beam channels is controlled by a light chopper; when the part is molded, controlling the angle of a reflector at the corresponding position on the light shield according to the two-dimensional layer information in the z direction obtained after slicing in the step 2) so that the laser beam passes through or is reflected to the light absorption unit;
5) forming parts: obtaining corresponding shading control information according to the slice file obtained in the step 1), firstly obtaining a dimmer control data file according to the shading control information obtained from each layer of section, wherein the content of the data file is the simplest 0/1 code and represents the opening and closing of a shading hole; when the part forming is started, the controller reads the shutter control data of the first path, and controls the angle of the reflector according to 0/1 codes so as to determine whether the laser passes through the light shielding plate or is reflected and absorbed; and after the molding of the first path is finished, the data memory of the shading controller moves to the shading controller data of the second path to read, and whether the laser passes through the shading plate is controlled according to 0/1 codes, so that the process is continuously and repeatedly executed until the molding of the whole part is finished.
2. The line forming method for metal additive manufacturing according to claim 1, wherein in the step 5), aiming at higher requirement of forming precision, the content of the controller data file is no longer only a simple 0/1 code obtained according to the shading control information obtained from each layer section, but each data unit obtained according to the shading control information and the setting of process parameters is a two-dimensional matrix data file with data precision of 8 bits or even higher, and the information stored in each data unit comprises opening and closing of the shading hole, laser power, laser aperture and scanning speed; the controller is used for controlling the opening and closing of the light shield according to the data file, and adjusting all control modules in the whole forming process according to corresponding process parameters set by forming requirements of different positions of a formed part.
3. The metal additive manufacturing line forming method according to claim 1 or 2, wherein in the step 4), the closing of the corresponding laser beam channel is controlled by a shutter as follows: and 2) passing the laser linear array obtained in the step 2) through a light chopper, wherein the light chopper is structurally characterized in that m controllable reflectors which are the same as the laser linear array beam are arranged on a light shielding plate, and the aperture size of the light chopper is set to be the aperture size of the maximum facula of the beam-splitting laser.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2021252241A3 (en) * | 2020-06-10 | 2022-01-20 | Vulcanforms Inc. | Angled scanning of laser arrays in additive manufacturing |
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